State of the Society. SFSA Funding Sources

Transcription

1 State of the Society SFSA Annual Meeting Sunriver, OR SFSA Funding Sources 1980 SFSA (1) 1982 SFSA + DOC (2) 1990 SFSA + DOE + DOD (3) 2009 DOE, DOD, MTI, IEC, MS&T, Iowa, LWI 2010 AMC(CIR, CIDR & SWC), DOE, MS&T and Iowa plus ups, ARL armor, ManTech OSD, Benet, ACIPCO and Precision Castings plusups, Buy Castings, MTI

2 Research Funding $ (thousand) Iowa MS&T LWI ARL CMC AMC IEC Sponsor SFSA SFSA Sponsors Federal Federal Diversified The Future Research focused on new alloys, new processes, and performance assessment New markets such as wind and building construction New SFSA committees HR& Safety and Future Leaders

3 FeMnAl Fe 30Mn 9Al 1Si 0.9C 0.5Mo Austenitic Age hardenable Lightweight Castable Oxidation resistant Good notch toughness FeMnAl Properties Alloy Heat Treat Condition BHN Yield Strength (MPa/ksi) Tensile Strength (MPa/ksi) % Elongation 1% Si Sol n Treat / / hr 530 C / / hr 530 C 372 1,005 / 145 1,065 / % Si Sol n Treat / / hr 530 C / / hr 530 C 384 1,016 / 147 1,085 / 157 5

4 FeMnAl Impact Properties wt.%p Solution treated & quenched Aged 10 hrs at 530 C 39 J at -40 C P greater than 0.03 wt.% 5-7 J NLOS C Material Requirements One pound savings at muzzle reduces breech end weight by 7 pounds HY130 FeMnAlC 0.1% offset yield 965 MPa 890 MPa (0.2%) % Reduction in area 25% - CVN at -40 C 35 J 39 J Weight of casting 373 lbs 325 lbs

5 Alloy Development High strength duplex Titanium Comparison ρ (lb/in3) UTS (ksi) YS (ksi) EL (%) E (10 6 psi) UTS/ρ Norm UTS/ρ Ti 6Al 4V Cast & HIP % % 17 4 PH H925 H % 9% % 66% 4340 Q&T 315C % % 300M* % % Custom 465* % %

6 17 4 Modifications Alloy additions N, V, Nb, Co Processing Homogenization time Austenite conditioning temperature Quenching media Age hardening time and temperature 17 4 Mod Properties Parameter Achieved Target UTS, MPa (ksi) 1352 ±46.5 (196± 6.7) YS,MPa (ksi) 1068± 23.2 (155± 3.5) 1310 (190) 1034 (150) % Elongation 10.33±1 5 CVN, J (ft-lb) Room temperature 9.53±3.2 (7.03±2.36) 13.6 (10)

7 17 4 Mod Goals: High Strength Good Impact Toughness / Ductility Homogeneity of Properties/Phase Formations Goal Elements: Methodologies: 17 4 Mod Properties

8 Foam Shell Process Ceramic shell casting for large, complex steel castings Development of foam and shell material, and processing Leveraging Processes % Area covered by Porosity Cast Acipco Forged Forged Benet Cast + HIPed Acipco Forged samples have lower microporosity than cast Microporosity in the Cast + HIPed sample is the least

9 Improving Toughness Charpy Impact Test Values (ft-lbs) y = x R 2 = Fraction of Area Covered by Inclusions Reduce inclusions through Calcium treatment Argon ladle stirring NDE Quality ensured through: Modeling Quantitative standards R&R of methods Planned research: Visual inspection technique Radiographic standard NDE standard based on part performance

10 Average One-Sided Student-t 95% Confidence Interval Radiography Rating Variation Data from all foundries 39 x-rays Average X-ray Level < x-rays 0.5 < Xavg < x-rays 1.5 < Xavg < x-rays < Xavg < 3.5 Average X-ray Level Groupings 8 x-rays 3.5 < Xavg < 4.5 Average one-sided student-t 95% confidence interval for all 128 x-rays = 1.42 Unanimous agreement 37% type, 17% level, 12.5% both (correlated with highly sound/unsound) 8 x-rays Xavg > 4.5 New Standard Development lineruler directionloading direction L l 1i

11 Research at Work Army Opportunities

12 Military Opportunities Tooling Database Sourcing Database Foundry Toolkit Population: Cast Tooling Database companies 18,600 tooling records Utilized by Supply Centers Assist defense contractors in finding tooling 50% success rate of matching inquiries to patterns/suppliers Company notified each time the government is buying parts for which they have tooling $1.5 million in orders directed to participants each month

13 Casting Suppliers Database Online directory of metalcasters serving the defense industry Utilized by government and defense contractors 256 Registered Metalcasters All Processes & Materials Casting bid solicitations matched to plant capabilities Foundry Toolkit for Gov t Business Online source that assists suppliers to: Learn DLA e commerce processes Establish required supplier accounts View solicitations Access tech data packages Submit quotes Understand procurement process Locate pre and post award assistance Find Business Opportunities

14 Identifying Opportunities Part Search Database Defensecastingtoolkit.com/partsearch.htm Online source that assists foundries to: Quickly identify casting NSN s Associate prospect list with DIBBS user account Determine anticipated demand Leverages CAST IT, DSCR & DSCC databases 7,000+ casting NSN s Routinely updated Building Construction Seismic building construction code now contains Appendix A for steel castings API SC2 offshore cast node standard completed September 18 th was Steel Day

15 Wind 100% ductile iron $.70/pound 30 tons castings/mw ,000 MW installed ,000 MW planned 20% by MW to 3 5 MW (larger castings) Advantages of steel castings Weldable Stiffness Higher properties UI R&D proposal Future Leaders A peer to peer network for the future leaders of steel foundries Meetings focus on foundry tours and graybeard discussions, along with a roundtable discussion Next meeting will be Milwaukee in October

16 HR and Safety Regulations and Working Practices are changing all the time. The only way to stay up to date is to stay up to date on the requirements. Foundries are at the top of the OSHA Hit List. The most concerted pressure is in the area of Record Keeping and Arc Flash Join the Safety Committee for up to date information and networking. Research Portfolio SFSA IEC MTI AMC ESMARRT Iowa MUS&T LWI Hot Tears Leaks CIR CIDR Melt Effy Hot Tears Instrume ntation Surface Corrosion CCT Lost Foam Design HSS P900 Press risers Niyama Weld HSS Process Foam Foam Performance Sand data Alloy develop

17 What do you get? Improve yield Reduce hot tears Reduce corrosion test rejections Improve product flow Replace Ti with steel Rapid patternmaking Qualify as a supplier with solidification simulation Vendor Approval region of leak

18 How do you get it? Sign your people up for membership of the Research Committees (Carbon & Low Alloy and High Alloy) They will have direct access to the researchers Customer Expectations How do you ensure that your customers do not order a product that cannot be made? Negotiate specifications that make sense ASTM Negotiate specifications that make sense ISO Work with your customer MTI Send your people to the ASTM meetings and join the SFSA Specifications Committee

19 Problem Solving SFSA Technical Service if you have a problem, we can have one of the SFSA researchers investigate the problem at no cost to you T&O The central part of the SFSA activities The National T&O Conference Once again we expect to have approximately 40 papers over 2 ½days with a ½day Workshop The only conference in the world devoted to the manufacture of steel castings.

20 Networking It is difficult to quantify the value Yet it is the most cost effective and efficient way of transferring knowledge and experiences. Send your people to meetings Didn t you come in part to Network? SFSA Membership number thousand dollars 0 Members Plants Dues

21 Revenues and Expenses 2000 Thousands $ Revenues Expenses SFSA Finances $1,000,000 $900,000 $800,000 $700,000 $600,000 $500,000 $400,000 $300,000 $200,000 $100,000 $ Investments Net Assets

22 SFSA Structure Income Reduced staff Geared to manage federal programs Labor expensed to programs IS staff for e transition Dues Meetings Projects Misc. Investments